Woven fabric



April 5, 1960 K. K. MASTERS WOVEN FABRIC Filed Dec. 12, 1955 SARAH 7 FIG.5

WEFT

INVENTOR: KATHERINE K. MASTERS bjaW-A/ W ATT'YS United States Patent WOVEN FABRIC Katherine K. Masters, Gurnee, Ill. Application December 12, 1955, Serial No. 552,480 6 Claims. (Cl. 139-423) This invention relates to woven fabrics, and particularly, to a fabric woven of both staple fiber threads and synthetic continuous filament threads. The threads are Woven in a manner which makes very advantageous use of the properties of each type of thread.

This application is a continuation-in-part of my copending patent application Serial No. 265,740, filed January 10, 1952, now abandoned, which in turn is a continuation-in-part of my application Serial No. 18,500 filed April 1, 1948, which was copending with the latter and is now abandoned.

it is an important object of the invention to provide a fabric woven of both staple fiber threads and synthetic continuous filament threads so that one side of the fabric presents a surface of staple fiber threads and the other a surface of synthetic continuous filament threads.

An addition object is to provide a fabric having a water-repellent or non-absorbent surface, while the other surface may be relatively water-absorbent.

Another object is to provide a fabric which is relatively stiff or resists bending about one axis, and may also resist bending about an axis normal thereto.

A further object is to provide a fabric which resists bending about one aids and which is also elastic or stretchable in the direction of the axis.

A particular object is to make use of the desirable properties of synthetic continuous filament threads while overcoming the disadvantages thereof by weaving with staple fiber threads.

Another object is to provide a fabric having a pleasing appearance due to a glossy surface and which also has useful properties of water repellency and stiffness.

An additional object is to provide a fabric which is advantageous in a variety of applications. The fabric is especially useful in the construction of foundation garments and panels thereof. It is also useful where water repellency and/ or resistance to blows or other destructive forces are desired.

These and other objections, advantages and functions of the invention will be apparent on reference to the specification taken in conjunction with the accompanying drawings illustrating preferred embodiments of the invention, in which like members are identified by like reference characters in each of the views, and in which Figure 1 is an exploded perspective view of a piece of fabric according to one embodiment of the invention;

Figure 2 is a side elevational view taken on line 2-2 of Figure 1;

Figure 3 is a side elevational view taken on line 3-3 of Figure 1;

Figure 4 is a side elevational view corresponding to Figure 3 but illustrating synthetic continuous filament threads in the warp, in place of the elastic threads or strands illustrated in the foregoing views;

Figure 5 is a top plan view of the embodiment of Figure 4, but illustrating the appearance of the fabric as Woven;

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Figure 6 is a side elevational view corresponding to Figure 4, but illustrating another embodiment; and

Figure 7 is an elevational view of a foundation garment constructed according to the invention.

In the invention, staple spun fiber threads, synthetic continuous filament threads and intermediate threads are united with staple spun fiber threads in such a manner that one surface of staple spun fiber threads and one surface of synthetic continuous filament threads are presented. The synthetic threads are interwoven with and bound to staple threads to produce a fabric which does not suffer from the usual disadvantages that accompany the use of synthetic continuous threads. Thus, the synthetic threads are prevented from slipping, loosening and rearranging, body is given to the fabric, and the synthetic threads are shielded by the staple threads. Water repellency, stiffness, and pleasing appearance are imparted to the fabric, and protection is afforded by the synthetic threads, while absorbency and softness are imparted by the staple threads.

The new fabric is woven of substantially linear warp threads interspaced with undulating staple spun fiber warp threads, and there are substantially linear staple spun fiber weft threads beneath or on one side of the linear warp threads and substantially linear synthetic continuous filament weft threads on top of or on the other side of the linear warp threads. The undulating threads are interwoven with the weft threads to provide a bottom surface of staple spun fiber threads and a top surface of synthetic filament threads.

In applications of the fabric where water repellency is especially desirable, the synthetic thread surface is preferably predominantly composed of the synthetic thread, as in the embodiments illustrated in the drawings. Additional water repellency is imparted by the provision of synthetic threads in the warp, as the linear warp threads referred to above. Where water repellency is not so important but stiffness is desired, the amount of synthetic thread at that surface need not be so great, provided that the incidence of synthetic threads in parallel relation is suificient to resist bending about an axis normal to the threads. In this case, synthetic threads may or may not also be provided in the direction of the latter axis, depending upon whether or not stiffness is also desired about an axis normal to the first axis. Instead of the second set of synthetic threads, elastic threads or strands can be used, to impart elasticity or stretchability in their direction, which is desirable in the construction of certain panels of foundation garments.

The weft threads are preferably provided in pairs of opposed parallel substantially linear threads separated by the substantially linear warp threads, with the staple threads on one side and the continuous threads on the other side of the linear warp threads. The undulating warp threads, which are interspaced with the linear warp threads, are interwoven with the pairs of weft threads so that the undulating threads pass over one pair and under the adjoining pair of each of the adjoining pairs of weft threads.

Referring to the drawings, Figure 1 illustrates a fabric according to the invention, generally indicated by the numeral 1. Substantially linear warp threads 2 are provided in pairs of adjacent, contiguous or contacting threads, and in the embodiment of Figures 1 to 3 the linear warp threads consist of a rubber strand 3 wrapped with a fine cotton thread 4 (Figure 2). Instead of pro viding the linear warp threads 2 in pairs, a single strand may be used in each location to provide the elastic characteristics. By reference to the several threads as being substantially linear, it is meant to contrast their arrangement with the undulating threads and indicate that they fof a different type synthetic. warp Ho not'p'ass over and under other threads alternately as in the case of a standard 'woven fabric. Instead, the threads are disposed substantially in one plane.

Substantially linear synthetic continuous filament weft threads 5, preferably of Saran, overlie the threads 2, and substantially linear staple spun fiber weft threads 6, preterably of cotton, underlie the linear warp threads. The linear staple weft threads, the linear continuous weft threads, and the linear intermediate warp 'threads are woven or bound together by interwoven undulating'staple spun fiber warp threads 7, preferably of cotton, which pass over one pair of opposed parallel Weft threads and 6 and under the adjoining pair of weft threads. 'Ada eless,

j'acent undulating warp threads respectively pass over and under individual pairs of weft threads.

The fabric construction and performance are specially good when groups of three adjacent or contiguous undulating warp threads are provided, as illustrated in Figure *1. However, a lesser or a greater number may also be used. In' this connection, it will be observed that the good weaving properties and the resulting desirable fabric eonstructionare imparted to a large extent by the staple spun fiber threads. The synthetic continuous filament threads are difiicult to weave satisfactorily, and fabrics previously woven with the synthetic threads often suffer from several disadvantages. The use of the staple threads and the use of linear synthetic threads in the manner illustrated combine to overcome the difficulties and dis- "advantages. V

The fabric woven in the foregoing manner is a closely "woven fabric having one relatively smooth surface prefdoininantly of synthetic continuous filament thread and the other surface entirely of staple spun fiber thread. The staple thread surface is especially even and smooth, 'as thejst'aple weft fibers ,yield to the tension of the undulatingwarp fibers. The fabric is stretchable in the directi'on'of the warp and readily bends or folds along an extending in the direction of the weft, but is relatively non-stretchable in the direction "of the 'weft and resists *b'en'ding or is relatively stiff about an axis in the direction "of the warp, so that it tends to lay flat. Such a fabric is especially well suited for use in various panels in foundation igarments where elasticity in one direction and stifiness in another are'de'sired. It may also be used to advantage in elastic bandages and the like. n '-In the embodiment'illustrate'd in Figures 4 and 5, the elastic warp threads 2 have Ibeenreplaced by synthetic continuous filament warp threads 8, preferably of saran, which may be'the same as the synthetic weft threads S or or size. This additional provision of synthetic threads in the warp provides resistance to bend- "ing'about a perpendicular axis, and the fabric-is no longer stretchable in the direction of the warp. This weave finds application infthe same types of articles as does that 'having elastic Warp threads, where elasticity is not desired and particularly, Where resistance to bending in both directions is desired. This embodiment is especially useful where water repellency is more important, as the threads present further water repellent surfaces, between the synthetic weft threads. The construction also afiords greater protection against destructive forces and presents a glossier appearance.

The fabric provided with the synthetic warp threads 8 is especially advantageous in its ability to shed liquids such as water and to dry quickly after being wetted. These qualities make the fiber well suited for use as tent -material, tarpaulins, gun covers, and in various ways as a substitute for canvas and protective coverings. The

' fabric is water repellent or resistant, although-it is not "water-proof, inthe manner of impervious sheets, such as of rubber or synthetic resins. The fabric ispermeable 'to water and gases, but substantially all of a stream or spray of water will be shed or repelled from the'synthetic thread surface.

Figure 6 illustrates a fabric woven of threads of the same type as the threads illustrated in Figure 4, butthc linear synthetic warp threads 8 alternate regularly with the undulating staple warp threads 7, every other warp thread being a staple thread and alternating with the synthetic threads. In this weave, the individual synthetic threads, both in the warp and in the weft, are separated from adjacent synthetic threads by parallel or normal staple threads.

Figure 7 illustrates a girdle, generally indicated by the numeral 9, "having panels made from the new fabric. In this embodiment, the girdle has at waist panel 10 and a front panel 11 made of the fabric. Either or both of the panels can be made fromfabric woven according to any of the embodiments illustrated in Figures 1 to 6. In any event, the fabric in the panels: is preferably arranged so thatsynthetic threads extend or run in the vertical direction, referring to the upright position of the garment or the position on the body as worn, to resist bending about a horizontal axis. In this manner, the panels replace stays, ribs and the like which have previously been incorporated in the garments. The support ismuch more uniform and comfortable and there are other advantages. 7 v

The fabric is also arranged in the panels and in the garment so that the surface of staple thread, corresponding to threads 6, is on the interior of the garment, next to the wearer, While the synthetic thread surface is on the exterior. In this manner, the inner surface is soft, comfortable and moisture-absorbent, and this constitutes an important advantage of the invention. 7 Use of the fabric in the panel 10, with synthetic threads running vertically, keeps the waist panel in place :andresists the natural tendency for it to roll or curl, providing the desired figure control and appearance. The waist panel then preferably is constructed 'o f t'he fabric of Figure 1, with the elastic warpthreads 2 extending tr'an'sversely or horizontally, so that the panel will stretch in that direction. The front panel 11 may be woven accord ing to Figures 1-3 or, where stretching is not desired, a'c'c'ording to Figures 4-6. The new fabric i's'also-useful 'in a variety 'of other garments, especially foundation garments. For example, it is useful in waist slenderizers, maternity foundations and in corsetry, in front, side and back panels.

The staple spun fiber threads or yarns 6 and 7 are relatively soft and flexible, and they provide good weav ing properties and a tight weave. The staple threads separate and lockthe synthetic continuous thre'ads, so that the disadvantages ordinarily associated with the-use of the latter are obviated and they accomplish 'their-desired funtions, particularly Water repellency and stiffness, in anunusually successful '-manner. The staple threads are preferably absorbent, and they are, for example, cotton, preferably, or regenerated cellulose, wool, -silk,-0r acetate silk.

The synthetic continuous filament threads are water repellent or substantially non-absorbe'nt, and they are extruded, drawn or spun'filament threads. They may be synthetic thermoplastic continuous filaments. The term synthetic resin is employed herein in the strict sense, that is, to mean a resin formed by synthesis using nonresinous organic materiais as reactants, as defined by Ellis (The Chemistry of Synthetic Resins, volume I, 1935, pages 12 and 13,-Reinhold Publishing'Corp. New York). The synthetic threads may be formed, for example, from the linear polyarnides, the vinylpolymers and copolymers, and the acrylonitrile polymers, including sat-an, pref- 'erably, and nylon, 'Orlon and dynel.

In the preferred embodiment, 'thersynthetic' threads are substantially non-elastic and the filament thickness is such assua e which imparts stiffness also furnish protection against blows and other destructive forces, for example, in butchers aprons for protection against knife cuts, and in various straps and the like which are subjected to rough usage. The synthetic filament or thread thickness may be from about 0.003 to 0.035 inch. In applications such as foundation garments, the thread diameter is preferably about 0.003 to 0.015 inch. Where protection against exterior forces is desired, a thickness in excess of about 0.008 inch is preferred. The elastic threads or strands 2 are preferably about 0.001 to 0.030 inch in diameter. The staple t reads are the usual sizes and may be varied to suit the intended use of the fabric.

The new woven fabric construction may have a pleasing and highly indestructive finish by virtue of the synthetic filament threads on one side, and they may have a lustrous sheen, depending on the filament used. The effect is especially pronounced where synthetic threads are used in both the warp and the weft, as illustrated at 8 and 5. The results are very useful in foundation garments and the like, and they find other applications as well, such as novelty fabrics in shoes and purses. These features combine with the stiifness and water rcpellency to provide a very desirabie fabric. A number of useful articles are constructed therewith, particularly, foundation garments, where the fabric serves to replace stays and ribs in the panels thereof.

The water repellent properties of the fabric make it desirable for applications where it will be exposed to the elements. The synthetic threads are not substantially wetted by water, and they dry rapidly. This provides a considerable improvement in tenting, gun covers, tarpaulins and so forth, which otherwise become wet and very heavy and remain so for a considerable period of time. In the tropics, this results is rapid rotting. The new fabric dries much quicker and resists rotting for a longer time under such conditions. At the same time, the fabric has the advantage of providing a soft, yielding and moisture-absorbent surface which may contact the body, is advantageous for straps and the like, such as a saddle girth, and may contact and move relative to articles covered with the fabrics.

The invention is hereby claimed as follows:

1. A woven fabric comprising pairs of opposed parallel substantially linear staple spun fiber and substantially linear synthetic continuous filament weft threads separated by substantially linear warp threads with the staple threads on one side thereof and the continuous threads on the other, and undulating staple spun fiber warp threads interspacing said linear warp threads and interwoven with said pairs of weft threads, the undulating threads passing over one pair and under the adjoining pair of each of the adjoining pairs of weft threads, the threads of each said pair being in superimposed relationship.

2. A woven fabric as defined in claim 1 wherein said substantially linear warp threads are synthetic continuous filament threads.

3. A woven fabric as defined in claim 1 wherein said substantially linear warp threads are elastic threads.

4. A woven fabric comprising pairs of opposed parallel substantially linear cotton and substantially linear synthetic continuous filament weft threads separated by substantially linear warp threads with the cotton threads on one side thereof and the continuous threads on the other, and undulating cotton warp threads interspacing said linear warp threads and interwoven with said pairs of weft threads, the undulating threads passing over one pair and under the adjoining pair of each of the adjoining pairs of weft threads, the threads of each said pair being in superimposed relationship.

5. A woven fabric comprising pairs of opposed parallel substantially linear cotton and substantially linear saran continuous filament weft threads separated by substantially linear warp threads with the cotton threads on one side thereof and the saran threads on the other, and undulating cotton warp threads interspacing said linear warp threads and interwoven with said pairs of weft threads, the undulating threads passing over one pair and under the adjoining pair of each of the adjoining pairs of weft threads, the threads of each said pair being in superimposed relationship.

6. A foundation garment having a panel of a woven fabric comprising pairs of opposed parallel substantially linear staple spun fiber and substantially linear synthetic continuous filament weft threads separated by substantially linear warp threads with the staple threads on one side thereof and the continuous threads on the other, and undulating staple spun fiber warp threads interspacing said linear warp threads and interwoven with said pairs of weft threads, the undulating threads passing over one pair and under the adjoining pair of each of the adjoining pairs of weft threads, the threads of each said pair being in superimposed relationship, thereby providing a bottom surface of staple spun fiber threads and a top surface of synthetic continuous filament threads, said bottom surface being on the interior of said garment and said top surface on the exterior, and said weft threads running in the vertical direction.

References Cited in the file of this patent UNITED STATES PATENTS 1,459,547 Moore et al June 19, 1923 2,103,133 Adamson Dec. 21, 1937 2,177,439 Moore Oct. 24, 1939 2,204,094 Meier June 11, 1940 2,557,315 Schiappa June 19, 1951 

